Fan for Air Conditioner

ABSTRACT

Fan apparatus including a fan, a shaft coupled to the fan for transmission of driving force from a motor to the fan, a rotor bushing of an insulating material joined to a rear end portion of the shaft, a rotor joined to the rotor bushing for transmission of the driving force to the shaft through the rotor bushing, and a stator mounted so as to be positioned on an inside of the rotor to form a BLDC motor together with the rotor, thereby reducing noise and enhancing fan efficiency by employing the BLDG motor which can make stable operation of the fan and increase an air flow rate.

TECHNICAL FIELD

The present invention relates to fan apparatuses for air conditioners, and more particularly, to a fan apparatus having a stable and high efficiency BLDC motor employed therein for enhancing fan, and heat exchange efficiencies.

BACKGROUND ART

In general, in the air conditioners, there are split type air conditioners each having an indoor unit and an outdoor unit respectively installed in a room space and an outdoor separately, and unit type air conditioners each having an indoor unit and an outdoor unit fabricated as one unit, for installation on a window or wall, wherein the split type air conditioners are used widely because, not only of sizes of the indoor units and the outdoor units that become the larger as cooling/heating capacities of the air conditioners become the larger, but also of heavy vibration of the outdoor units corning from compressors therein.

The split type air conditioner is provided with the indoor unit in a room to make heat exchange between low temperature, and low pressure gaseous refrigerant and air for supplying warm or cold air into a space to be air conditioned, the outdoor unit in an outdoor to compress, condense, and expand the refrigerant for making the heat exchange at the indoor unit, and refrigerant pipelines between the indoor unit and the outdoor unit.

The indoor unit is provided with an indoor case having an inlet and an outlet for drawing/discharging room air, an evaporator in the indoor case for making heat exchange between the low temperature, and low pressure gaseous refrigerant passing therethrough and air, and an indoor fan and a motor on one side of the evaporator for making room air to pass the evaporator so that cold air is discharged to the room again.

The outdoor unit is provided with an outdoor case having inlets and an outlet for drawing/discharging outdoor air, a compressor in the outdoor case for compressing high temperature, high pressure gaseous refrigerant passed through the evaporator, a condenser for making heat exchange between the refrigerant passed through the compressor with outdoor air to condense the refrigerant into medium temperature, high pressure liquid refrigerant, expansion means, such as a capillary tube, or an electronic expansion valve for decompressing the refrigerant passed through the condenser into low temperature, low pressure gaseous refrigerant, and an axial outdoor fan and a motor on one side of the condenser for making the outdoor air to pass the condenser, wherein the motor is a single phase, or three phase induction motor having a stator mounted on an inside of a housing, and a shaft and a rotor in a central part of the stator for rotating the rotor by a rotating magnetic field formed as AC is applied to the stator.

In general, the outdoor case has the inlets in three sides for enhancing a fan efficiency, and the outlet in a top surface, for drawing air through the three sides, making the air to heat exchange, and discharging the air to the top surface.

The compressor, the condenser, the expansion means, and the evaporator are connected with the refrigerant pipelines to each other, for circulation of the refrigerant therethrough while the refrigerant is compressed, condensed, expanded, and evaporated.

In the meantime, the foregoing outdoor unit of the related art air conditioner has a limited installation place due to high concentration of a city, with consequential strengthening of environmental control, and becomes an object of complaints due to noise and heat emission. Particularly, for an apartment in a large group of apartment houses, installation of the air conditioner is regulated such that the outdoor unit is installed within a veranda due to outside appearance and noise.

Consequently, air conditioner outdoor units of a front suction/discharge type are employed in the large group of apartment houses recently, in which air is drawn only through a front, made to heat exchange, and discharged to the front, again.

However, the air conditioner outdoor units of a front suction/discharge type has low fan, and heat exchange efficiencies due to a smaller air suction area than the air conditioner outdoor unit of three side suction/discharge type.

Moreover, the general single phase or three phase induction motor used for the fan of the air conditioner outdoor unit of the front suction/discharge type has problems in that an overall efficiency is low below 40˜50%, and rotation speed variation is limited to a small range due to a narrow stable torque range. If a rotation speed is outside of the stable torque range, noise becomes heavier and efficiency becomes poorer.

DISCLOSURE OF INVENTION

An object of the present invention is to provide a fan apparatus for an air conditioner which can reduce noise, and enhance a fan efficiency, and a heat exchange efficiency by employing a BLDC motor that can make stable drive of the fan, and increase an air flow rate.

The object of the present invention can be achieved by providing a fan apparatus including a fan, a shaft coupled to the fan for transmission of driving force from a motor to the fan, a rotor bushing of an insulating material joined to a rear end portion of the shaft, a rotor joined to the rotor bushing for transmission of the driving force to the shaft through the rotor bushing, and a stator mounted so as to be positioned on an inside of the rotor to form a BLDC motor together with the rotor.

In another aspect of the present invention, a fan apparatus includes a fan housing of synthetic resin, a fan mounted on an inside of the fan housing, a shaft coupled to the fan mounted on an inside of the fan housing for transmission of driving force from a motor to the fan, a supporter having a bearing housing of a metal and a stator securing portion extended from the bearing housing in a radial direction for fastening the stator thereto, the supporter being inserted in an upper surface of the fan housing at the time of injection molding of the fan housing, a rotor coupled to a rear end portion of the shaft, and a stator securely mounted on the supporter so as to be positioned on an inside of the rotor to maintain concentricity with the rotor.

BRIEF DESCRIPTION OF DRAWINGS

The accompanying drawings, which are included to provide a further understanding of the invention, illustrate embodiment(s) of the invention and together with the description serve to explain the principle of the invention.

In the drawings;

FIG. 1 illustrates a perspective view of a fan apparatus for an air conditioner in accordance with a preferred embodiment of the present invention;

FIG. 2 illustrates a reference perspective view of an assembly of a BLDC motor and a supporter in a state the assembly is separated from a fan housing and a fan;

FIG. 3A illustrates a section of a fan apparatus in accordance with a preferred embodiment of the present invention;

FIG. 3B illustrates a partial enlarged view of the motor and the supporter in FIG. 3A;

FIG. 4A illustrates a perspective view of the supporter in FIG. 3A;

FIG. 4B illustrates a bottom perspective view of FIG. 4A;

FIG. 5 illustrates a partial perspective view showing a state in which a vibration damping member is mounted on a supporter securing portion of a supporter;

FIG. 6 illustrates a perspective view of a fan apparatus for an air conditioner in accordance with another embodiment of the present invention;

FIG. 7A illustrates a section of FIG. 6;

FIG. 7B illustrates an enlarged view of key parts of FIG. 7A;

FIG. 8A illustrates a perspective view of a sirocco fan in accordance with a preferred embodiment of the present invention;

FIG. 8B illustrates a plan view of FIG. 8A;

FIG. 9A illustrates a perspective view of a rotor applied to the present invention, with a partial cut away view for showing an inside structure;

FIG. 9B illustrates a bottom perspective view of FIG. 9A;

FIG. 10A illustrates a perspective view of a rotor bushing applied to the present invention;

FIG. 10B illustrates a bottom perspective view of FIG. 10A;

FIG. 11 illustrates a perspective view of a magnet applied to a rotor in accordance with another embodiment of the present invention;

FIG. 12 illustrates a perspective view of a stator applied to the present invention;

FIG. 13 illustrates a disassembled perspective view of FIG. 12;

FIG. 14 illustrates a perspective view of a helical core, as an enlarged view of the core in FIG. 13;

FIG. 15 illustrates a perspective view of another example of a stator applicable to the present invention;

FIG. 16 illustrates a perspective view of a split core, as an example of the core structure in FIG. 15;

FIG. 17 illustrates a perspective view of another example of a stator applicable to the present invention;

FIG. 18 illustrates a perspective view of a one pieced core, as an example of a core structure in FIG. 17;

FIG. 20 illustrates a perspective view showing an installation state of an air conditioner outdoor unit of a front suction/discharge type having a fan apparatus of the present invention applied thereto, with a partial cut away view;

FIG. 21 illustrates a disassembled perspective view showing an installation state of an air conditioner outdoor unit of a front suction/discharge type having the fan apparatus of the present invention applied thereto; and

FIG. 22 illustrates a front view showing an installation state of an air conditioner outdoor unit of a front suction/discharge type having the fan apparatus of the present invention applied thereto.

BEST MODE FOR CARRYING OUT THE INVENTION

Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings. In describing the embodiments, identical parts will be given to the same names, and additional and repetitive description of which will be omitted.

FIG. 1 illustrates a perspective view of a fan apparatus for an air conditioner in accordance with a preferred embodiment of the present invention, FIG. 2 illustrates a reference perspective view of an assembly of a BLDC motor and a supporter in a state the assembly is separated from a fan housing and a fan, FIG. 3A illustrates a section of a fan apparatus in accordance with a preferred embodiment of the present invention, and FIG. 3B illustrates a partial enlarged view of the motor and the supporter in FIG. 3A.

Though the fan in FIG. 3A shows a half section, with a bushing therein showing only a half accordingly, the bushing has a disc shape with symmetric left and right sides actually as shown in FIG. 8B.

FIG. 4A illustrates a perspective view of the supporter in FIG. 3A, FIG. 4B illustrates a bottom perspective view of FIG. 4A, and FIG. 5 illustrates a partial perspective view showing a state in which a vibration damping member is mounted on a supporter securing portion of a supporter.

FIG. 8A illustrates a perspective view of a sirocco fan in accordance with a preferred embodiment of the present invention, FIG. 8B illustrates a plan view of FIG. 8A, FIG. 9A illustrates a perspective view of a rotor applied to the present invention, with a partial cut away view for showing an inside structure, and FIG. 9B illustrates a bottom perspective view of FIG. 9A.

FIG. 10A illustrates a perspective view of a rotor bushing applied to the present invention, FIG. 10B illustrates a bottom perspective view of FIG. 10A, and FIG. 11 illustrates a perspective view of a magnet applied to a rotor in accordance with another embodiment of the present invention.

FIG. 12 illustrates a perspective view of a stator applied to the present invention, FIG. 13 illustrates a disassembled perspective view of FIG. 12, and FIG. 14 illustrates a perspective view of a helical core, as an enlarged view of the core in FIG. 13.

The fan apparatus 1 in accordance with a first preferred embodiment of the present invention includes an outside case 10, a fan housing 40 of steel plate secured to an inside of the outside case 10 having air inlets 410 a and 410 b in top and bottom, and an air outlet in a front, a sirocco fan 50, a centrifugal fan, mounted on an inside of the fan housing 40, a shaft 68 fixed to the sirocco fan 50, for transmission of power from a motor to the sirocco fan 50, bearings 69 a and 69 b for supporting the shaft 68, a supporter 80 secured to an upper surface of the fan housing 40, for supporting the bearings 69 a and 69 b and a stator 65, a rotor bushing 70 of an insulating material secured to an opposite end portion of a fan connecting portion of the shaft 68, a rotor 60 secured to the rotor bushing 70 for transmission of power to the shaft 68 through the rotor bushing 70, and the stator 65 securely mounted on the supporter 80 inside of the rotor 60 so as to maintain concentricity to the rotor 60 to construe a BLDC motor 6 together with the rotor 60.

Sides of the outside case 10 facing the air outlet and the air inlets 410 a, and 410 b of the fan housing 40 are opened, and a grill G is mounted on an opened side facing the air outlet of the fan housing 40.

In the meantime, the fan housing 40 includes an air inlet 410 a in a bottom, and an air inlet 410 b in a top spaced a distance from the bottom, which can also be used as an opening for mounting a motor, and an air outlet in one of sidewalls which connect the bottom and the top and surround the sirocco fan 50.

In the meantime, the sirocco fan 50 is mounted in the fan housing 40 such that an axis of the fan housing 40 is eccentric from an axis of the fan housing 40. That is, the axis of the fan housing 40 is not coincident with the axis of the sirocco fan 50, but spaced from the axis of the sirocco fan 50. Therefore, as can be noted in FIG. 3A, left and right side spaces between the fan housing 40 and the sirocco fan 50 differ.

Between the outside case 10, and the fan housing 40, there is a supporting bracket 11 for supporting the fan housing on the outside case 10. Though it is preferable that the supporting bracket 11 is extended from the outside case 10 as one unit and fastened to the top of the fan housing 40, the supporting bracket 11 may be placed between the outside case 10 and the fan housing 40 as a separate member.

Referring to FIG. 1, the fan housing 40 has a reinforcing forming portion 430 substantially along a circumference direction with a width varied with a top surface of the fan housing 40 which becomes the greater as it comes to a wider portion (a front side of the outside case).

In the meantime, there are shrouds 44 respectively mounted on the air inlet 410 a in the bottom of the fan housing 40 and the air inlet 410 b in the top of the fan housing 40 that also serves as a motor mounting opening, for guiding air flow introduced into the fan.

Though a case of the shroud 44 is shown as an example, in which each of the shrouds 44 includes, as separate members, a fastening surface 440 a for fastening to a periphery of the top or bottom air inlet 410 a or 410 b of the fan housing 40, and a guide 440 b of a predetermined curvature for guiding an air flow, the shrouds 44 may be formed as one unit with the fan housing 40. In this case, the shroud 44 has a thickness that becomes the thinner compared to other portion as it goes toward an end the farther.

In the meantime, referring to FIGS. 3A, 3B, and 4, the supporter 80, preferably of a cast metal, such as aluminum, includes a bearing housing portion 82 having shaft 68 supporting bearings 69 a and 69 b, such as ball bearings, mounted therein, supporter securing portions 86 each extended outwardly in a radial direction from the bearing housing portion 82 for securing the supporter 80 to the top of the fan housing 40, and a stator 65 securing portion formed so as to join the supporter securing portions 86 to form a surface for securing the stator 65 thereto.

That is, the supporter securing portion 86 of the supporter 80 has a tripod shape.

Moreover, it is required that the supporter 80 is bent toward a top portion of the fan housing 40 such that ends of the supporter securing portions 86 are positioned above a stator fastening surface, for positioning at least the stator fastening surface of the supporter inside of the fan housing 40 when the supporter is mounted on the fan housing 40.

The supporter 80 has reinforcing ribs 88 a for reinforcing a strength of the supporter securing portion 86, preferably connected also to the stator securing portion 84, and an outside circumferential surface of the bearing housing portion 82.

The supporter 80 and the stator 65 have positioning projections and positioning holes 842 respectively formed opposite to each other for aligning concentricity of the supporter 80 and the stator 65 in fastening the stator 65 to the supporter 80. In more detail, the stator securing portion 84 of the supporter 80 have the positioning holes 842 for fixing a fastening position of the stator 65, and the stator 65 facing the stator securing portion 84 has the positioning projections (see 656 b in FIG. 12). Of course, the positioning projections may be formed on the supporter, while the positioning holes may be formed on the insulator of the stator.

In the meantime, the stator securing portions 84 of the supporter 80 have pass through holes 844 for enhancing motor cooling capability.

Of steps 822 a and 822 b on an inside circumferential surface of the bearing housing portion 82, the step 822 a at a lower portion has a “┐” shape for supporting an upper end of the lower bearing 69 a of the bearings mounted on outside circumferential surfaces of the shaft 68, and of steps 822 a and 822 b on an inside circumferential surface of the bearing housing portion 82, the step 822 b at an upper portion has a “└” shape for supporting a lower end of the upper bearing 69 b of the bearings mounted on outside circumferential surfaces of the shaft 68.

The shaft 68 inside of the bearing housing portion 82 for transmission of power from the rotor 60 to the fan housing 40 may have positioning steps at an upper portion and a lower portion of an outside circumferential surface for positioning the lower bearing and the upper bearing at the shaft 68.

Referring to FIGS. 3A, 3B, and 5, it is preferable that vibration damping pads 46 are provided at contact surfaces of the fan housing 40 and the shrouds 44.

In more detail, the vibration damping pads 46 are mounted between the fastening surfaces 440 a of the shrouds 44 and peripheral surfaces of the air inlets 410 a and 410 b of the fan housing 40 in contact thereto, for cutting off transmission of vibration from the motor to the fan housing 40.

A vibration damping member 90 is provided between the supporter securing portion 86 of the supporter 80 and the fan housing 40.

Referring to FIG. 5, the vibration damping member 90 includes a body portion 920 a in contact with the fan housing 40, and a head portion 920 b to be forcibly inserted through a vibration damping member securing hole 866 in the supporter securing portion 86 and held at the supporter securing portion 86. There is a pass through hole 930 through the body portion 920 a and the head portion 920 b.

It is preferable that a cover bracket 95 of metal, such as steel plate, is placed on the head portion 920 b of the vibration damping member 90 to the vibration damping member 90 caused by fastening force on a fastening member, such as a bolt 15 d, passed through the vibration damping member 90 at the time the supporter 80 is secured to the fan housing 40.

The cover bracket 95 is a horse shoe shaped steel piece to cover the head portion 920 b.

That is, the vibration damping member 90 is secured as a neck portion between the body portion 920 a and the head portion 920 b is caught at an edge of the vibration damping member securing hole 866 when the head portion 920 b is forcibly pushed through the vibration damping member securing hole 866 in the supporter securing portion 86. In this state, after the cover bracket 95 is placed on the head portion 920 b, the bolt 15 d is passed through the pass through hole 930 in the cover bracket 95 and the vibration damping member 90, and fastened to the fan housing 40, to secure the supporter 80 to the fan housing 40.

Referring to FIGS. 3A, 3B, 8A, and 8B, the sirocco fan 50 includes a main plate 54 for connecting blades 52 arranged on an inside of the fan along a circumferential direction thereof, having a bushing 56 at a central portion thereof for coupling the shaft 68 to the sirocco fan 50.

At a lower end and an upper end of the blades 52, there are holding plates 53 a and 53 b for holding the blades together for preventing the blades from shaking at fast rotation of the fan and noise caused thereby.

The bushing 56 includes a base portion 560 a of a disc shape in close contact with a main plate 54 surface, and a hub portion 560 b projected from a central portion of the base portion 560 a in an axis direction, and having a shaft 68 inserting hole at the central portion.

The bushing 56 has two pieces, which are riveted with rivets 58 or fastened with screws in a state the two pieces are closely fitted to opposite sides of the main plate 54.

The main plate 54 is mounted at a position nearer to the motor with reference to the middle of a length of the sirocco fan 50. This is because, of the air inlets 410 a and 410 b of the fan housing 40, an air flow rate through the air inlet 410 a opposite to a side the motor is mounted thereon is higher.

It is preferable that the main plate 54 is positioned such that, in a case an entire length of the sirocco fan 50 between two fan ends is divided into two lengths with reference to the main plate 54, a ratio of a short length from the main plate 54 to a fan end to a long length from the main plate 54 to the other fan end falls within a range of 1:1.3˜1:3.

The hub portion 560 b of the bushing 56 has at least one bolt fastening hole 560 c in an outside circumference, and the shaft 68 has a flat section 685 at an outside circumference of an end portion for applying a compression force of the bolt 15 f passed through, and fastened to the bolt fastening hole 560 c in assembly.

Therefore, in assembly, as the compression force of the bolt is applied to the flat section 685, the sirocco fan 50 is secured to the shaft 68 rigidly enough to rotate as one unit.

On an outside circumference of an end portion of the shaft 68 on a side the fan is coupled thereto, there may be a positioning projection (not shown) or a positioning step (not shown) of the bushing with respect to the shaft. That is, at the time of assembly of the shaft and the sirocco fan, as the positioning projection or the positioning step on the shaft is caught at the hub portion of the bushing, the shaft can be inserted no more, bringing the flat section to a bolt fastening position automatically, as well as fixing a position of the sirocco fan within the fan housing.

Referring to FIGS. 3A, and 3B, though it can be noted that the rotor bushing 70 is joined with the shaft 68 and the rotor frame 60 a in a state the rotor bushing 70 is positioned under the rotor frame 60 a, the rotor bushing 70 may be joined with the shaft 68 and the rotor frame 60 a in a state the rotor bushing 70 is positioned over the rotor frame 60 a.

In the meantime, referring to FIGS. 10A and 10B, the rotor bushing 70 includes a tooth portion 72 having a central portion for inserting and engagement of the shaft 68 therewith, and a joining portion 74 extended from a circumference of the tooth portion 72 in a radial direction for joining with the rotor frame 60 a.

The joining portion 74 of the rotor bushing 70 has a plurality of positioning projections 740 formed as one unit therewith for inserting into the positioning holes 602 g in the rotor frame 60 a in assembly.

The joining portion 74 of the rotor bushing 70 also has fastening holes 742 for fastening to the rotor frame 60 a with bolts.

The tooth portion 72 and the joining portion 74 of the rotor bushing 70 have reinforcing ribs 76 a and 76 b respectively.

The shaft 68 has serration 680 on an outside circumferential surface of the top end portion, and the rotor bushing 70 has serration 720 on an inside circumferential surface of a central hole in the tooth portion 72, for engagement with the serration 680 of the shaft 68.

That is, the rotor bushing 70 is fastened to the rotor frame 60 a with fastening members such as bolts or the like passed through the fastening holes 742 in the joining portion 74, and the shaft 68, inserted through the central portion of the tooth portion 68 and connected to the rotor bushing 70 with serration engagement, is fastened to the rotor bushing 70 with the bolt 15 b inserted into the fastening hole at an end portion thereof.

In the meantime, the rotor bushing 70 is formed of synthetic resin having a vibration mode different from the rotor frame 60 a of steel plate.

Referring to FIGS. 3A, 3B, 9A, and 9B, the rotor 60 includes a rotor frame 60 a, and magnets 60 b mounted on an inside thereof, wherein the rotor frame 60 a is preferably formed of steel plate taking productivity and formability into account.

However, material of the rotor frame is not limited to above, but the rotor frame 60 a may be formed by injection molding, or a steel plate and an injection molding that covers an outside of the steel plate.

The rotor frame 60 a includes a bottom portion 602 of a substantially disc shape, and a sidewall portion 604 extended in a substantially vertical direction from a circumference of the bottom portion 602, wherein the sidewall portion 604 has a bent portion 604 a formed along a circumferential direction having a seating surface for supporting magnets 60 b mounted on an inside surface thereof, and the bottom portion 602 has a hub portion 602 a having a pass through hole 602 b at a central portion for pass of fastening members, such as bolts 15 b, for fastening the rotor 60 to the shaft 68.

The bottom portion 602 of the rotor frame 60 a also has fastening holes 602 h in correspondence to the fastening holes 742 in the joining portion 74 of the rotor bushing 70.

In the meantime, the bottom portion 602 of a substantially disc shape, and the sidewall portion 604 extended in a substantially vertical direction from a circumference of the bottom portion 602 of the rotor frame 60 a are formed as one unit by pressing, if the rotor frame 60 a is formed of a steel plate.

In this instance, the sidewall portion 604 has an opened end edge bent in a radial direction outwardly for the first time, and bent again downwardly toward the bottom portion 602 for the second time.

The bent portion 604 b at the opened end edge of the sidewall portion 604 of the rotor frame 60 a enhances rigidity of the sidewall portion 604, and prevents distortion of the rotor occurred at a time of fast rotation, and noise caused thereby in advance.

The rotor frame 60 a has a plurality of cooling fins 602 c around the hub portion 602 a in a radial direction for blowing air toward the stator 65 to cool heat generated at the stator 65 when the rotor 60 rotates. The cooling fin 602 c has a predetermined length in a radial direction.

In the meantime, the cooling fins 602 c are formed by lancing, such that the cooling fins 602 c are directed toward the opening, and pass through hole 602 d formed by the lancing serve as vent holes.

The cooling fin 602 c is bent at 90° to the bottom portion 602 such that the cooling fin 602 c is directed toward the opening of the rotor 60.

The rotor frame 60 a has embossed portions 602 e in the bottom portion 602 between adjacent cooling fins 602 c for reinforcing the rotor frame 60 a, each with a drain hole 602 f for draining water.

In the meantime, as shown in FIG. 9A, the magnet 60 b has an arc shape, or as shown in FIG. 11, or the magnet 60 b has a ‘C’ shape (with reference to a substantial ‘C’ form of a curved portion).

Referring to FIGS. 3B, 13, and 14, the stator 65 includes an annular helical core 65 a of a multiple layer structure of a steel plate with ‘T’s 654 a and a base portion 652 a wound in a helix starting from a bottom layer to a top layer, an insulator 65 b enclosing the core for making insulation, and having a joining portion 655 b projected toward an inner side of the core with fastening holes for fastening the stator 65 to the fan housing 40 with fastening members, such as bolts 15 c, and a coil 65 c wound on the ‘T’s 654 a.

In this instance, the joining portion 655 b of the stator has more than three projections toward the inner side of the core, and has a height more than 20% of a total height of the core.

Referring to FIG. 13, this is because the height more than 20% of a total height of the core of the joining portion 655 b of the insulator is adequate for enduring vibration from the motor if the core has no other joining portion.

In the meantime, the joining portion 655 b may have metal tubes 65 d, or instead of the metal tubes 65 d, spring pins (not shown) each having a longitudinal incision to have radial direction elasticity, respectively inserted in the fastening holes of the joining portion 655 b.

The helical core 65 a has a multiple layered structure wound in a helix starting from a bottom layer to a top layer, wherein a plurality of the T's 654 a are projected outwardly in a radial direction from the base portion 652 a, and the base portion 652 a has trapezoidal or rectangular slots 656 a for reduction of stress in winding the core.

Multiple layers of the helical core 65 a are held together with rivets 657 a passed through pass through holes in the base portion 652 a, and a winding start portion and a winding end portion of the helical core 65 a are welded to predetermined portions of the base portion in contact thereto, respectively.

Referring to FIG. 13, the insulator 65 b has separate upper and lower pieces, for enclosing the core as the upper and lower pieces are held together.

In a case the insulator 65 b is fabricated as separate upper and lower pieces, the insulator 65 b includes an insulator upper 650 b secured to an upper side of the core, and an insulator lower 651 b secured to a bottom of the core to cover the bottom.

On the other hand, the insulator 65 b may be fabricated, not as the separate upper and lower pieces, but fabricated by molding at a time, when the core is processed in a state the core is inserted in a synthetic resin.

The operation and blowing process of the foregoing fan apparatus of the present invention will be described.

When rotation of the rotor 60 is caused as a current flows to the coil 65 c of the stator of the BLDC motor 6 in a sequence through a power connection tap housing assembly 300, the shaft 68 engaged to the rotor bushing 70 which is joined with the rotor 60 with serration rotates, to transmit power to the sirocco fan 50 through the shaft 68 to rotate the sirocco fan, causing the air to be drawn through the upper and lower inlets 410 a and 410 b in the top and bottom of the fan housing 10, and to be discharged through the outlet O in the front of the outside case 10.

In detail, as current is applied to the coil 65 c of the stator 65 in the BLDC motor 6, electro-magnetic force is generated between the stator 65 and the magnet 60 b, when a sensor keeps detecting a position of the magnet 60 b, to apply the current to the coils 65 c of the stator 65 in succession, so that the electro-magnetic force is kept generating between the stator 65 and the magnet 60 b, to rotate the rotor 60 having the magnet 60 b secured thereto together with the shaft 68 fixed to the rotor 60, thereby transmitting a rotation force to the sirocco fan 50.

In this instance, since the BLDC motor 6 has a wide range of stable torque characteristic, the BLDC motor 6 can, not only be operated at various rotation speeds, but also reduce noise as the BLDC motor 6 makes stable operation, and moreover, reduce power consumption.

As the sensor for motor control, a hole sensor 200 is used.

In summary, the fan apparatus 1 of the present invention discharges air in a circumferential direction after drawing the air through the bottom air inlet 410 a of the fan housing 40 and drawing a portion of the air through the top air inlet 410 b of the fan housing 40 when the sirocco fan 50 is rotated by the BLDC motor 6, and the discharged air is guided by the fan housing 40, until the air is discharged through the outlet O in the outside case 10.

In the meantime, the fan apparatus of the present invention has the following advantages.

The employment of the BLDC motor 6 which is stable at most of rotation speeds and has a high efficiency in driving the fan of the fan apparatus 1 enables to drive the BLDC motor while varying the rotation speeds widely, and reduce noise and power consumption as stable and high efficiency operation can be made in an entire rotation speed range.

Moreover, by effective mounting and securing of the BLDC motor 6 at one side of the fan housing having a low suction air flow rate by using separate supporter 80, with a portion of the BLDC motor sunken in the fan housing 40, the fan apparatus 1 of the present invention has an advantage of reducing an overall size of the fan apparatus.

The direct motor coupling type fan apparatus 1 enables to reduce noise, occurrence of faults, and power consumption, and product reliability is enhanced because the bearing housing is formed of metal, such as aluminum, that has no thermal distortion.

Since the rotor 60 of a steel plate of the fan apparatus 1 enables to form by pressing, with a good formability, and short fabrication time period, productivity is improved.

The fan apparatus 1 of the present invention enables easy fabrication of the rotor 60 because the sidewall portion 604, extended vertically from a circumference of the bottom portion 602 of the rotor frame 60 a, has a bent portion 604 a formed along a circumferential direction having a magnet 60 b seating surface, that permits secure supporting of the magnets 60 b when the magnets 60 b are attached to the inside surface of the rotor.

Moreover, the plurality of radial cooling fins 602 c each with a predetermined length around the hub portion 602 a of the rotor frame 60 a blow air toward the stator, to cool down heat generated at the stator 65.

The cooling fins 602 c are formed to direct toward the opening of the rotor 60 by lancing, and the pass through holes 602 d formed by the lancing serve as vent holes.

The easy formation of the rotor 60 of a steel plate by one time of pressing enables to shorten a time required for fabrication of the rotor, that improves productivity.

The first outward radial direction bending and the second downward bending of the opening end of the sidewall 604 of the rotor frame 60 a enhances strength of the rotor frame 60 a, to prevent distortion of the rotor 60 and occurrence of noise caused thereby.

Along with this, the embossed portions 602 e between adjacent cooling fins 602 c on the bottom portion 602 of the rotor 60 improve an overall strength of the rotor 60, and the drain holes 602 f in the embossed portions 602 e enable draining of water to an outside of the motor.

The rotor bushing 70 of the present invention of an injection molded synthetic resin having a vibration mode different from the rotor frame 60 a of steel plate enables to dampen vibration of the rotor 60 in transmission to the shaft 68.

The helical core 65 a which allows easy winding prevents waste of material, and enhances easy fabrication, and rigidity of the stator securing portion 84 of the supporter 80 is increased to reduce noise and vibration, to improve mechanical reliability and lengthen a lifetime.

That is, since the slots 656 a in the base portion 652 a of the helical core 65 a in the stator 65 reduce stress in winding the core, the winding can be done easily with a low power.

Moreover, referring to FIGS. 12, and 13, the height of the joining portion 655 b of the insulator 65 b of synthetic resin more than 20% of a total core height permits to have an adequate rigidity even if no metal core present to the joining portion, to prevent breakage of the joining portion 655 b caused by vibration occurred during operation of the motor.

Particularly, it is preferable that the joining portion 655 b has a height the same with a total height of the core.

Though the height of the joining portion 655 b may be higher than the total height of the core, it is preferable that the height of the joining portion 655 b is set not to exceed two times of the total height of the core because an excessive height of the joining portion 655 b increases a total height of a driving unit of the fan apparatus, which is not favorable for fabricating a compact fan apparatus.

The positioning projections 656 b on the joining portion 655 b matched to the positioning holes 842 in the supporter 80 enable easy joining of the stator 65.

That is, the present invention permits not only a rigid securing of the stator 65 to the supporter 80, but also effective maintenance of concentricity of the stator.

The fan apparatus 1 of the present invention permits low cost and easy fabrication because the fan housing 40 is formed of a metal plate that is strong against heat, and light.

Furthermore, the fan apparatus 1 of this embodiment can enhance a fan efficiency because the BLDC motor 6 is mounted on a side of the air inlet 410 b having a relatively low flow suction rate of the air inlets 410 a and 410 b of the fan housing 40, that enables, not only to minimize a suction flow resistance, but also high efficiency stable operation.

A fan apparatus in accordance with a second preferred embodiment of the present invention will be described with reference to FIGS. 6 to 18.

In describing the embodiment, parts identical to the first embodiment will be given the same names, and additional, and repetitive description of which may be omitted.

The fan apparatus in accordance with a second preferred embodiment of the present invention includes an outside case 10, a fan housing 40 of synthetic resin secured to an inside of the outside case 10 having air inlets 410 a and 410 b in top and bottom, and an air outlet in a front, a sirocco fan 50, a centrifugal fan, mounted on an inside space of the fan housing 40, a shaft 68 fixed to the sirocco fan 50, for transmission of power from a motor to the sirocco fan 50, bearings 69 a and 69 b for supporting the shaft 68, a supporter 80′ insert molded with an upper surface of the fan housing 40, for supporting the bearings 69 a and 69 b and a stator 65, a rotor bushing 70 of an insulating material secured to an opposite end portion of a fan connecting portion of the shaft 68, a rotor 60 secured to the rotor bushing 70 for transmission of power to the shaft 68 through the rotor bushing 70, and the stator 65 securely mounted on the supporter 80′ inside of the rotor 60 so as to maintain concentricity to the rotor 60 to construe a BLDC motor 6 together with the rotor 60.

Sides of the outside case 10 facing the air outlet and the air inlets 410 a, and 410 b of the fan housing 40 are opened, and a grill G is mounted on an opened side facing the air outlet of the fan housing 40.

In the meantime, the fan housing 40 includes an air inlet 410 a in a bottom, and an air inlet 410 b in a top spaced a distance from the bottom, which can also be used as an opening for mounting a motor, and an air outlet in one of sidewalls which connect the bottom and the top and surround the sirocco fan 50.

In the meantime, alike the first embodiment, the sirocco fan 50 is mounted in the fan housing 40 such that an axis of the fan housing 40 is eccentric from an axis of the fan housing 40. Therefore, left and right side spaces between the fan housing 40 and the sirocco fan 50 differ.

Between the outside case 10, and the fan housing 40, there is a supporting bracket 11 for supporting the fan housing on the outside case 10. Though it is preferable that the supporting bracket 11 is extended from the outside case 10 as one unit and fastened to the top of the fan housing 40, the supporting bracket 11 may be placed between the outside case 10 and the fan housing 40 as a separate member.

In the meantime, there are shrouds 44′ respectively mounted on the air inlet 410 a in the bottom of the fan housing 40 and the air inlet 410 b in the top of the fan housing 40 that also serves as a motor mounting opening, for guiding air flow introduced into the fan.

Together with this, on the upper surface of the fan housing 40, there are ribs 400 in a circumferential direction as well as a radial direction for reducing weight of the fan housing while reinforcing strength of the fan housing.

Referring to FIG. 7B, the supporter 80′ insert molded with the upper surface of the fan housing includes a bearing housing portion 82 having shaft 68 supporting bearings 69 a and 69 b, such as ball bearings, mounted therein, a stator securing portion 84 extended outwardly in a radial direction from the bearing housing portion 82 to provide a surface for securing the stator 65 thereto, and a supporting portion 86 extended from the securing portion 84, and buried under a peripheral surface of the air inlet which also serves as a pass through hole for mounting the motor in the fan housing. That is, the supporter 80′ substantially has a tripod shape when seen from above. It is preferable that the supporter 80′ is a cast of metal, such as aluminum.

Moreover, the supporter 80′ has a middle portion between the stator securing portion 84 and an end portion of the supporter bent toward a top portion of the fan housing 40 such that the surface of the stator securing portion 84 is not projected beyond the upper surface of the fan housing 40.

There is a boss projected from a circumference of each of fastening holes in the upper surface of the fan housing 40 for preventing direct contact with the stator securing portion of the supporter, thereby preventing damage of the insulator of the stator 65 by fastening force applied when the stator is fastened.

The supporter 80′ has reinforcing ribs 88 a, and 88 c (see FIG. 7B) for reinforcing a strength of the supporter and enhancing a joining force with the synthetic resin in insert injection molding.

The supporter 80′ and the stator 65 have positioning projections and positioning holes 842 respectively formed in correspondence to each other for aligning concentricity of the supporter 80′ and the stator 65 in fastening the stator 65 to the supporter 80′.

As an example, the stator securing portion 84 of the supporter 80 have the positioning holes 842 for fixing a fastening position of the stator 65, and the stator 65 facing the stator securing portion 84 has the positioning projections (see 656 b in FIG. 12).

In the meantime, of steps 822 a and 822 b on an inside circumferential surface of the bearing housing portion 82, the step 822 a at a lower portion has a “┐” shape for supporting an upper end of the lower bearing 69 a of the bearings mounted on outside circumferential surfaces of the shaft 68, and of steps 822 a and 822 b on an inside circumferential surface of the bearing housing portion 82, the step 822 b at an upper portion has a “└” shape for supporting a lower end of the upper bearing 69 b of the bearings mounted on outside circumferential surfaces of the shaft 68.

The shaft 68 inside of the bearing housing portion 82 for transmission of power from the rotor 60 to the fan housing 40 may also have positioning steps at an upper portion and a lower portion of an outside circumferential surface for positioning the lower bearing and the upper bearing at the shaft 68.

Since the operation and advantages of the fan apparatus of the foregoing embodiment is almost the same with the first embodiment, portions different from the first embodiment will be described at first.

First, the fan housing 40 of synthetic resin injection molding can reduce weight of the fan housing.

Next, the insert molding of the supporter 80′ at the time of injection molding of the fan housing of synthetic resin enables to omit a separate supporter assembly step.

Different from the first embodiment, the formation of the fan housing of synthetic resin injection molding enables to omit the vibration damping members and the vibration damping pads.

In the meantime, the fan apparatus 1 of the present invention has the same operation and advantages with the first embodiment in the following points of view.

The employment of the BLDC motor 6 which is stable at most of rotation speeds and has a high efficiency enables to reduce noise and power consumption as stable and high efficiency operation can be made.

The mounting of a portion of the BLDC motor sunken in an inside of the fan housing 40 enables to reduce an overall size of the fan apparatus.

The bearing housing of metal without thermal distortion enhances product reliability.

Since the rotor 60 of a steel plate of the fan apparatus 1 enables to form by pressing, with a good formability, productivity is improved.

The fan apparatus 1 of the present invention enables easy fabrication of the rotor 60 because the seating surface makes secure seating of the magnets 60 b when the magnets 60 b are attached to the inside surface of the rotor.

Moreover, the plurality of radial cooling fins 602 c around the hub portion 602 a of the rotor frame 60 a blow air toward the stator 65, to cool down heat generated at the stator 65.

The first outward radial direction bending and the second downward bending of the opening end of the sidewall 604 of the rotor frame 60 a enhances strength of the rotor frame 60 a, to prevent distortion of the rotor 60.

Along with this, the embossed portions 602 e between adjacent cooling fins 602 c on the bottom portion 602 of the rotor 60 improve an overall strength of the rotor 60, and the drain holes 602 f in the embossed portions 602 e enable draining of water to an outside of the motor.

The rotor bushing 70 of the present invention of synthetic resin having a vibration mode different from the rotor frame 60 a of steel plate enables to dampen transmission of vibration to the shaft 68.

The helical core 65 a which allows easy winding prevents waste of material, and enhances easy fabrication.

That is, since the slots 656 a in the base portion 652 a of the helical core 65 a in the stator 65 reduce stress in winding the core, the winding can be done easily with a low power.

Moreover, referring to FIGS. 12, and 13, the height of the joining portion 655 b of the insulator 65 b of synthetic resin more than 20% of a total core height permits to have an adequate rigidity even if no metal core present to the joining portion, to prevent breakage of the joining portion 655 b caused by vibration occurred during operation of the motor.

The positioning projections 656 b on the joining portion 655 b matched to the positioning holes 842 in the supporter 80 enable easy joining of the stator 65.

Moreover, the fan apparatus of the embodiment permits, not only a rigid securing of the stator 65 to the supporter 80 of synthetic resin, but also effective maintenance of concentricity of the stator.

Meanwhile, different from above embodiment, instead of inserting a whole supporter 80′, the bearing housing portion 82 of the supporter may be inserted in the upper surface of the fan housing in injection molding of the fan housing, while the stator securing portion 84 is exposed to an outside of the upper surface of the fan housing when the fan housing is injection molded.

In the meantime, FIG. 19 illustrates a perspective view of another embodiment of a supporter 80″ having a basic configuration identical to the one in FIGS. 4A and 4B, even if a shape thereof is slightly different from the one in FIGS. 4A and 4B.

In this case the reinforcing ribs are different from the reinforcing ribs in FIGS. 54A and 4B. Upon comparing to FIGS. 4A, and 4B, it can be noted that a position of the reinforcing rib 88 a is different.

It can be noted that, while FIGS. 4A and 4B illustrate a case when only one reinforcing rib 88 a is formed on a center line of a surface of each of the stator securing portions 84, FIG. 19 illustrates a case when the reinforcing ribs 88 a are formed on opposite sides of the surface of each of the supporter securing portions 86.

Moreover, though no detailed example is shown, the supporter 80 may only include a bearing housing portion 82 on an inside of shaft 68 supporting bearings, and a stator securing portion 84 extended in a radial direction from the bearing housing portion 82 for securing both the supporter on a top surface of the fan housing 40, and the stator on an opposite side thereof.

That is, this case is a case when the stator securing portion 84 is extended to the supporter securing portions, such that the supporter securing portions 86 are not in a spoke shape, but in a disc shape.

In the meantime, FIG. 15 illustrates a perspective view of another example of a stator applicable to the present invention, and FIG. 16 illustrates a perspective view of a split core, as an example of the core structure in FIG. 15. In the case of the stator 65′ in FIG. 15, instead of the helical core 65 a, a split core is used.

The split core 65 a′ is fabricated by forming divided core pieces each divided along a circumferential direction on a mother work piece of a steel plate having the T's 654 a and the base portion 652 a, and connecting the divided core pieces with welding.

‘W’ in the drawing denotes a welded portion.

In this case, though an insulator 65 b of divided pieces held together is shown, the core may be inserted molded such that the insulator encloses the core, completely.

In the meantime, FIG. 17 illustrates a perspective view of another example of a stator applicable to the present invention, and FIG. 18 illustrates a perspective view of a one pieced core, as an example of a core structure in FIG. 17, wherein the stator 65″ in FIG. 17 illustrates a case of one pieced core 65 a″ of a steel plate with the T's 654 a and the base portion 652 a, having no cut along a circumferential direction, instead of the helical core 65 a, or the split core. The one pieced core is illustrated in FIG. 18.

Though FIG. 17 illustrates a case when the core is inserted molded such that the insulator encloses the core completely, the insulator of divided pieces held together as shown in FIG. 16 can be used.

In the meantime, in above embodiment, the sirocco fan 50 is fastened to the shaft 68 so as to be rotatable with the shaft 68 as an end of a bolt passed through the bolt fastening hole 560 c is pressed onto the flat section at the outside circumference of the end of the shaft 68. However, not only such a fastening structure enables fastening of the sirocco fan 50 to the shaft 68.

Though not shown, in the same principle of configuration in which the rotor bushing 70 and the shaft 68 passed through a central portion thereof are held together with the bolt 15 b, the sirocco fan 50 and the shaft 68 may be held together with a bolt that passes through a central portion of the main plate 54 of the sirocco fan 50, and an end of the shaft 68.

An example of application of the fan apparatus 1 to the air conditioner outdoor unit of the front suction/discharge type will be described with reference to FIGS. 20˜22.

FIGS. 20˜22 illustrate a perspective view with a partial cut away view, a disassembled perspective view, and a front view showing installation states of the air conditioner outdoor unit of the front suction/discharge type, respectively.

Referring to FIGS. 20˜22, the air conditioner outdoor unit of the front suction/discharge type includes a case 10′ having an opened front and various parts held therein. The air conditioner outdoor unit of the front suction/discharge type is installed in a rectangular space in an outside wall 2 of a residential or commercial building.

In detail, securely mounted on an inside wall of the space in an outside wall 2 of the building is an outer frame 4, securely mounted on an inside of the outer frame 4 is an inner frame 5 (depending on cases, the outer and inner frames 4, and 5 may be formed as one unit), across a middle of an inside area of the inner frame 5 is a middle isolating bar 9 for dividing the inside area of the inner frame 5 into a inlet area 7 a and a outlet area 7 b in up/down direction, mounted in each of the areas is a plurality of louver blades 8 for suction/discharge of air between gaps of the blades 8, closely mounted on an inside of the inner frame 5 is the outdoor unit, and between the inner frame 5 and the outdoor unit is sealing member ‘S’ for preventing leakage of air and damping vibration.

The air conditioner outdoor unit of the front suction/discharge type installed thus includes an inlet ‘I’ and an outlet ‘O’ in a lower side and an upper side of the opened front of the case 10 a, a compressor (not shown) and a heat exchanger 20 built in on an inner side of the inlet ‘I’ for compression and condensing refrigerant, and a fan apparatus 1 built in on an inner side of the outlet ‘O’ for blowing air, wherein the fan apparatus 1 includes a sirocco fan 50, a kind of centrifugal fan, inside of a fan housing 40 securely mounted on an inner side of the outlet ‘O’ as a fan, and a BLDC motor 6 connected to the sirocco fan and securely mounted on the fan housing 40 with a separate supporter 80 for rotating the sirocco fan 50.

The case 10 a includes an inlet portion 11 a and an outlet portion 11 b in correspondence to the inlet area 7 a and the outlet area 7 b on inner sides of the inlet ‘I’ and outlet ‘O’ respectively, and preferably grills G on the inlet ‘I’ and the outlet ‘O’ of the opened front for preventing infiltration of large sized foreign matters, bugs, animals, and the like.

For reference, it can be noted that the case 10 a is slightly different from the outside case 10 of the fan apparatus described before, because the case 10 a is taken, not only the front suction, but also installation of a heat exchanger, and the like on an inside thereof into account.

Moreover, the case 10 a has various units, such as the compressor, and the heat exchanger 20 securely mounted on the inlet portion 11 a and the outlet portion 11 b with various shapes of brackets (not shown), and the case 10 a is mounted such that the opened front of the case 10 a is in close contact with the sealing member ‘S’ at an inside of the inner frame 5.

Of course, the compressor and the heat exchanger 20 are mounted so as to be connected to the heat exchanger (not shown) in the indoor unit with refrigerant pipelines, the other expansion means (not shown), such as capillary tube or expansion valve, are also mounted so as to be connected between the outdoor unit heat exchanger and the indoor unit with refrigerant pipelines. Above configuration enables the refrigerant to cool a space the indoor unit is installed therein as the refrigerant is compressed, condensed, expanded, and evaporated while the refrigerant circulates a refrigerating cycle with the compressor, the outdoor side heat exchanger 20, the expansion means, the indoor side heat exchanger.

The outdoor heat exchanger 20 has a plurality of ‘U’ bent refrigerant pipes with a plurality of cooling fins 602 c fitted thereto, the compressor mounted on an inner side, and a control box 30 on a rear side for controlling operation of various units in the outdoor unit.

The fan apparatus 1 is securely mounted on the outdoor unit heat exchanger 20, wherein, after the sirocco fan 50 and the BLDC motor 6 are connected to each other, the sirocco fan 50 and the BLDC motor 6 are securely mounted inside of the fan housing 40 with the supporter 80, and the fan housing 40 is securely mounted on the outdoor unit heat exchanger 20 so as to be positioned at the outlet 11 b of the case 10 a with a separate bracket (not shown).

In more detail, the sirocco fan 50 is a kind of centrifugal fan which draws air in an axial direction and discharges the air in a circumferential direction, and has an air flow rate relatively higher than an axial fan.

The sirocco fan 50 has a structure the same with the foregoing embodiment.

Next, the fan housing 40 has air inlets 410 a and 410 b in top and bottom for drawing air passed through the outdoor side heat exchanger 20 in an axial direction of the sirocco fan 50, preferably with shrouds 44 on the inlets 410 a and 410 b respectively for guiding the air, and an air outlet for discharging the air in a circumferential direction of the sirocco fan 50.

The air outlet in the fan housing 40 is in communication with the outlet ‘O’ in the case 10 a.

In the meantime, the BLDC motor 6, using, not a brush, but a driving circuit in converting AC to DC, has not sparks occurred and no hazard of gas explosion because the BLDC motor 6 has no brush, makes a stable driving in most of speed range, and has a high efficiency in a range of 70˜80%. In detail, the BLDC motor 6 includes a shaft 68 for transmission of power to the sirocco fan, a stator 65, a rotor 60, and magnets 60 b for generating rotating force by electro-magnetic force to drive the shaft 68, and a hole sensor 200 for detecting a position of the rotor 60, for controlling a current supplied thereto.

Particularly, the BLDC motor 6 is securely mounted on a side of the top air inlet 410 b of the fan housing 40 having a relatively low flow rate with the supporter 80 for reducing suction flow resistance.

In more detail, the shaft 68 is rotatably mounted supported on the supporter 80 with bearings 69 a and 69 b, such as ball bearings, in a state the shaft 68 is passed through the supporter 80, with an end thereof coupled to an upper shaft center of the sirocco fan 50 by bolt fastening, or caulking, and the stator 65 is securely mounted on the supporter 80, with a predetermined gap to an outside circumference of the shaft 68.

Along with this, the rotor 60 has an outside circumferential portion positioned around an outside circumference of the stator 65, and an inside circumference portion securely mounted on the shaft 68, wherein the rotor has a plurality of ribs, or embossed portions on a bottom extended in a radial direction for reinforcement against centrifugal force, a plurality of the permanent magnets 68 are securely mounted on an outside circumferential portion of the rotor 60 along a circumferential direction at regular intervals for generating electro-magnetic force with the stator 65, and the hole sensor 200 is securely mounted on a core side of the stator 65.

Therefore, if a current flows to the coils 65 c of the stator 65 in succession, the rotor 60 rotates by electro-magnetic force between the current in the coil and the magnet 60 b, and the rotation force of the rotor 60 rotates the sirocco fan 50 though the shaft 68.

Next, the supporter 80 mounts the sirocco fan 50 and the BLDC motor 6 hung from the fan housing 40 in an inside thereof. In detail, the supporter 80 includes a cylindrical bearing housing portion 72 having the shaft 68 rotatably mounted thereon by the bearings 69 a and 69 b, a stator securing portion 84 formed as one unit with the bearing housing portion 72 at an upper end thereof for securely mounting the stator 65 in a state the stator 65 is placed thereon, and a plurality of supporter securing portions 86 projected in a radial direction from a circumference of the stator securing portion 84 at regular intervals and fastened to a periphery of the air inlet 410 b in the top of the fan housing 40.

The bearing housing portion 72 of a cylindrical shape with a length shorter than the shaft 68 has the bearings 69 a and 69 b for rotatably supporting the shaft 68, and the stator securing portion 84 has a plurality of positioning holes 842 and fastening holes 846 for fastening screws in a state the stator 65 is inserted in an upper surface thereof.

Along with this, it is preferable that the supporter 80 has three supporter securing portions 86 around the bearing housing portion 82 and the stator securing portion 84 at 120° intervals for spreading load thereon, and a reinforcing rib 88 a is formed between the bearing housing portion, the stator securing portion 84, and the supporter securing portion 86 for supporting an underside of the stator securing portion 84 and the supporter securing portion 84 to reinforce a strength of the supporter securing portion 86, and it is more preferable that a plurality of supplementary reinforcing ribs 88 b and 88 c are formed on upper sides of the supporter securing portions, too.

Particularly, the supporter securing portions 86 are projected in a radial direction from the stator securing portion 84, and have middle portions each sloped upward the more as it goes toward the radial direction the farther, and horizontal end portions having a vibration damping member securing hole 866. Accordingly, the supporter 80 is mounted such that the supporter securing portions 86 are fastened to a periphery of the air inlet 410 b in a top of the fan housing 40.

A process for assembling the fan apparatus, a main unit of the present invention, and the operation of the outdoor unit will be described.

First, the BLDC motor 6 forms a motor assembly as the shaft 68 is rotatably mounted on the bearing housing portion 82 of the supporter 80 with the bearings 69 a and 69 b and the stator 65 is secured to the upper surface of the stator securing portion 84 with screws, and the motor assembly is mounted such that the shaft 68 is coupled to a shaft center of the sirocco fan 50 in a state the sirocco fan 50 is positioned inside of the fan housing 40, and the supporter 80 is mounted on the fan housing as the supporter securing portions 86 of the supporter 80 are placed on, and fastened to, the periphery of the top air inlet 410 b on the upper surface of the fan housing with bolts or the like.

Accordingly, the fan apparatus 1 having the BLDC motor 6 thereon is securely mounted on the outdoor heat exchanger 20 with a separate bracket in a state the fan apparatus 1 is placed thereon, and the BLDC motor 6 is connected to the control box 30 with wires for controlling operation of the BLDC motor 6.

With regard to the operation of the outdoor unit assembled thus, the compressor is operated in response to a signal from the control box 30, according to which the refrigerant is introduced into the indoor unit through the compressor, the outdoor heat exchanger 20, and the expansion means, and circulated along the indoor heat exchanger.

In this instance, since the refrigerant circulates through the outdoor heat exchanger 20, and the sirocco fan 50 is driven by the BLDC motor 6, the air drawn through the inlet ‘I’ in the case 10 a makes heat exchange with the refrigerant as the air passes through the outdoor heat exchanger 20, to condense the refrigerant, and passes the sirocco fan 50, and is discharged through the outlet ‘O’ in the case 10 a.

Of course, because the BLDC motor 6 has a wide range of stable torque characteristic, the BLDC motor 6 can make stable operation in a variety of speeds, enabling reduction of noise, and power consumption.

According to this, since the sirocco fan 50, a kind of centrifugal fan, draws air in an axial direction by driving such a BLDC motor 6, most of the air passed through the outdoor heat exchanger 20 is drawn through the bottom air inlet 410 a of the fan housing 40, and rest portion of the air is drawn through the top air inlet 410 b, and the air is guided by the shrouds 44 on the air inlets 410 a and 410 b to flow in an axial direction of the sirocco fan 50 and discharged in a circumferential direction, and, therefrom is guided by the fan housing 40 and discharged through the outlet ‘O’ in the case 10 a in communication with the air outlet in the fan housing.

Since the BLDC motor 6 is mounted on a side of the air inlet 410 b which has a lower air flow rate relatively of the air inlets 410 a and 410 b of the fan housing 40, not only a suction flow resistance can be minimized, but also fan efficiency and heat exchange efficiency can be enhanced as the BLDC motor makes stable operation at a high efficiency.

It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the spirit or scope of the inventions. Thus, it is intended that the present invention covers the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.

INDUSTRIAL APPLICABILITY

As has been described, the fan apparatus for an air conditioner of the present invention permits to drive the BLDC motor while varying a speed of the motor widely, and to reduce noise, and power consumption, because the BLDC motor is applied for driving the fan, which can make stable operation in most of rotation speeds and has a high efficiency.

Moreover, since the fan apparatus of the present invention permits effective mounting of the BLDC motor in the fan housing, with a portion of the BLDC motor sunken in an inside of the fan housing, an overall size of the fan apparatus can be reduced. 

1. A fan apparatus comprising: a fan; a shaft coupled to the fan for transmission of driving force from a motor to the fan; a rotor bushing of an insulating material joined to a rear end portion of the shaft; a rotor joined to the rotor bushing for transmission of the driving force to the shaft through the rotor bushing; and a stator mounted so as to be positioned on an inside of the rotor to form a BLDC motor together with the rotor.
 2. The fan apparatus as claimed in claim 1, wherein the fan is a sirocco fan including; a main plate on an inside of the fan for connecting blades formed along a circumferential direction; and a bushing at a center of the main plate for coupling the fan to the shaft.
 3. The fan apparatus as claimed in claim 2, wherein the bushing includes; a base portion of a disc shape in close contact with the main plate, and a hub portion projected in an axial direction from a center of the base portion, the hub portion having a shaft inserting hole at a center.
 4. The fan apparatus as claimed in claim 3, wherein, of the opposite sides of the main plate, the bushing is secured at least to the side of the main plate on a front side of the fan.
 5. The fan apparatus as claimed in claim 3, wherein the bushing includes two pieces riveted or fastened with screws in a state the two pieces are closely fitted to opposite sides of the main plate.
 6. The fan apparatus as claimed in claim 5, wherein the base portions brought into close contact with the opposite sides of the main plate are fastened together with riveting or screw fastening.
 7. The fan apparatus as claimed in claim 3, wherein the main plate is mounted at a position nearer to a motor side with reference to a middle point of a length of the fan.
 8. The fan apparatus as claimed in claim 3, wherein the hub portion has at least one bolt fastening hole in an outside circumference, and the shaft includes a flat section at an outside circumferential surface of an end portion of the shaft for positioning the bolt fastening hole thereon.
 9. The fan apparatus as claimed in claim 3, wherein the shaft includes a projection at an outside circumferential surface of an end portion of the shaft the fan is coupled thereto for fixing an inserting position of the bushing at the shaft.
 10. The fan apparatus as claimed in claim 1, wherein the rotor bushing is joined with the rotor frame in a state the rotor bushing is positioned on an inside of the rotor frame.
 11. The fan apparatus as claimed in claim 1, wherein the rotor bushing is joined with the rotor frame in a state the rotor bushing is positioned on an outside of the rotor frame.
 12. The fan apparatus as claimed in claim 9, wherein the rotor bushing includes; a tooth portion at a center portion for inserting and engagement with the shaft, and a joining portion around the tooth portion for fastening to the rotor frame.
 13. The fan apparatus as claimed in claim 11, wherein the rotor bushing further includes a plurality of positioning projections formed as one unit with, and extended from the joining portion toward the rotor frame.
 14. The fan apparatus as claimed in claim 11, wherein the rotor bushing has pass through holes in the joining portion for fastening to the rotor frame.
 15. The fan apparatus as claimed in claim 11, wherein at least one of the tooth portion and the joining portion of the rotor bushing further includes reinforcing ribs.
 16. The fan apparatus as claimed in claim 12, wherein the rotor frame includes positioning holes in correspondence to the positioning projections on the joining portion of the rotor bushing.
 17. The fan apparatus as claimed in claim 13, wherein the rotor frame has fastening holes in correspondence to the pass through holes in the joining portion of the rotor bushing.
 18. The fan apparatus as claimed in claim 2, wherein the sirocco fan is rotatably mounted in an inside space of the fan housing having air inlets and air outlet.
 19. The fan apparatus as claimed in claim 18, wherein the fan housing is formed of metal plate.
 20. The fan apparatus as claimed in claim 19, wherein the fan housing has the supporter secured thereto for supporting the stator.
 21. The fan apparatus as claimed in claim 20, wherein the supporter includes; a bearing housing portion having shaft supporting bearings mounted therein, and a supporter securing portion extended outwardly from the bearing housing portion to secure the supporter to an upper surface of the fan housing, and provide a surface for securing the stator thereto.
 22. The fan apparatus as claimed in claim 21, wherein the supporter securing portion of the supporter includes at least three radial direction extensions from the bearing housing portion.
 23. The fan apparatus as claimed in claim 20, wherein the supporter includes; a bearing housing portion having shaft supporting bearings mounted therein, supporter securing portions extended in a radial direction outwardly from the bearing housing portion for securing the supporter to an upper surface of the fan housing, and a stator securing portion formed to join the supporter securing portions for providing a surface for securing the stator thereto.
 24. The fan apparatus as claimed in claim 21, wherein the supporter securing portions have end portions bent toward an outside of the fan housing with reference to a stator fastening surface for positioning at least the stator fastening surface of the supporter on an inside of the fan housing when the supporter is mounted on the fan housing.
 25. The fail apparatus as claimed in claim 18, wherein the fan housing is formed of synthetic resin.
 26. The fan apparatus as claimed in claim 23, wherein the supporter of a metal is insert molded on a side opposite to a main air inlet in injection molding of the fan housing.
 27. The fan apparatus as claimed in claim 26, wherein the supporter includes; a bearing housing portion having shaft supporting bearings mounted therein, and a stator securing portion extended outwardly from the bearing housing portion to provide a surface for securing the stator thereto.
 28. The fan apparatus as claimed in claim 27, wherein the bearing housing portion of the supporter is inserted to an upper surface of the fan housing in injection molding of the fan housing, and the stator securing portion of the supporter is injection molded at the time of injection molding of the fan housing such that the stator securing portion is exposed to an outside of the upper surface of the fan housing.
 29. The fan apparatus as claimed in claim 26, wherein the supporter includes; a bearing housing inserted in an upper surface of the fan housing when the fan housing is injection molded, and a stator securing portion fabricated separate from the bearing housing, and joined to the upper surface of the fan housing or to the bearing housing.
 30. A fan apparatus comprising: a fan housing of synthetic resin; a fan mounted on an inside of the fan housing; a shaft coupled to the fan mounted on an inside of the fan housing for transmission of driving force from a motor to the fan; a supporter having a bearing housing of a metal and a stator securing portion extended from the bearing housing in a radial direction for fastening the stator thereto, the supporter being inserted in an upper surface of the fan housing at the time of injection molding of the fan housing; a rotor coupled to a rear end portion of the shaft; and a stator securely mounted on the supporter so as to be positioned on an inside of the rotor to maintain concentricity with the rotor.
 31. The fan apparatus as claimed in claim 1, wherein the stator includes; a multiple layered annular helical core of a steel plate having T's and a base portion wound in a helix starting from a bottom layer to a top layer, an insulator for enclosing the helical core, coils wound on T's on the helical core, respectively, and a joining portion formed as a unit with the insulator projected toward an inner side of the core, the joining portion having fastening hole for fastening the stator to the supporter.
 32. The fan apparatus as claimed in claim 31, wherein the joining portion includes at least three projections toward an inner side of the core.
 33. The fan apparatus as claimed in claim 32, wherein the joining portion has a height more than 20% of a total height of the core.
 34. The fan apparatus as claimed in claim 31, wherein the fastening holes in the joining portion has spring pins inserted therein.
 35. The fan apparatus as claimed in claim 31, wherein the fastening holes in the joining portion has metal tubes inserted therein.
 36. The fan apparatus as claimed in claim 27, wherein each of the fastening holes in the upper surface of the fan housing includes a boss projected from a circumference thereof for preventing direct contact with the stator securing portion of the supporter, thereby preventing damage of the insulator of the stator by fastening force applied when the stator is fastened.
 37. The fan apparatus as claimed in claim 27, wherein the supporter includes ribs on the supporter securing portion for enhancing a joining force with the synthetic resin at the time of injection molding, inserting the supporter in the upper surface of the fan housing.
 38. The fan apparatus as claimed in claim 31, wherein the helical core includes; a multiple layered structure wound in a helix from a bottom layer to a top layer, a plurality of T's projected in a radial direction outwardly from the base portion of the helical core, and slots in the base portion of the helical core for reduction of stress in winding the core.
 39. The fan apparatus as claimed in claim 38, wherein the multiple layers of the helical core are held together with rivets passed through pass through holes in the base portion.
 40. The fan apparatus as claimed in claim 38, wherein the helical core includes a winding start portion and a winding end portion welded to predetermined portions of the base portion in contact thereto, respectively.
 41. The fan apparatus as claimed in claim 38, wherein the recess has a rectangular or trapezoidal form. 